With the rapid development of the new energy vehicle (NEV) industry, the power battery, as its core component, directly determines the vehicle’s driving range, service life, and market competitiveness. During charging and discharging, power batteries generate a significant amount of heat. If this heat cannot be effectively managed and dissipated, it will lead to increased battery temperature, reduced performance, and even trigger thermal runaway and other serious safety hazards. Therefore, the scientific design of thermal management systems and the application of high-performance thermal management materials have become essential to ensuring the efficient and safe operation of power batteries.
I. Challenges in Power Battery Thermal Management
A power battery pack consists of hundreds or even thousands of individual cells arranged in a compact structure with high energy density. Under operating conditions such as fast charging/discharging, high-rate discharge, and high-temperature environments, uneven temperature distribution within the battery is particularly prominent, with localized overheating being a common issue. This non-uniformity not only accelerates battery aging and reduces cycle life but can also lead to thermal runaway, causing irreversible safety accidents. Therefore, power battery thermal management must possess multiple characteristics, including efficient heat conduction, uniform temperature control, structural compactness, lightweight design, and long-term reliability.
II. The Core Role of Thermal Management Materials in Power Batteries
Thermal management materials play a dual role in power battery systems as both “temperature regulators” and “safety guardians.” They are primarily used in key interfaces such as between cells and modules, between modules and liquid cooling plates, and inside the battery pack casing. Through functions such as heat conduction, insulation, buffering, and sealing, they ensure that heat is rapidly conducted and evenly dissipated, while protecting the battery from external physical and chemical environmental factors such as vibration, moisture, and dust.
OSI New Materials has developed a series of high-performance thermal management materials tailored to the needs of power battery thermal management, including thermally conductive structural adhesives, thermal potting compounds, and thermal pads. These materials play an irreplaceable role in improving battery thermal efficiency, extending service life, and enhancing safety protection.
III. Analysis of Key Thermal Management Material Applications
1. Thermally Conductive Structural Adhesive
Thermally conductive structural adhesive combines both structural bonding and thermal conductivity functions. It is widely used for fixing and conducting heat between cells and module brackets, and between modules and cooling plates. It not only provides sufficient mechanical strength to ensure the stability of the battery pack structure but also forms an efficient heat conduction path to rapidly transfer heat generated by the cells to the cooling system.
OSI’s thermally conductive structural adhesive utilizes high thermal conductivity fillers and modified resin systems, offering excellent thermal conductivity (up to 1.5–3.0 W/m·K), strong bonding strength, and aging resistance. It also meets the UL94 V-0 flame retardancy standard, providing dual protection of structural support and thermal management for the battery pack.
2. Thermal Potting Compound
Thermal potting compound is mainly used for potting and protecting the inside of battery modules or the entire battery pack. By completely encapsulating the cells and circuit components, it forms an integrated thermal and protective layer. It effectively fills internal voids, improves heat transfer efficiency, and provides excellent vibration resistance, shock absorption, moisture resistance, and dust protection, significantly enhancing the environmental adaptability and long-term reliability of the battery pack.
OSI’s thermal potting compound is based on a two-component silicone system, with adjustable thermal conductivity (1.0–2.5 W/m·K). After curing, it forms a soft elastomer with excellent electrical insulation and high-temperature stability, making it especially suitable for battery pack designs with complex structures and high safety requirements.
3. Thermal Pad
Thermal pads are pre-formed, flexible thermal conductive materials primarily used to fill irregular gaps between cells and cooling plates, or between modules and the casing. They are characterized by easy installation, good compressibility, and stable thermal performance. Their softness effectively buffers vibrational stress and protects the structural integrity of the cells.
OSI’s thermal pads are made from a silicone rubber base, with thermal conductivity reaching 3.0–6.0 W/m·K. They feature low thermal resistance, high insulation, and aging resistance, making them an ideal choice for lightweight design and efficient thermal management in battery packs.
IV. Future Development Trends
As power batteries evolve toward higher energy density, faster charging speeds, and longer service life, the demands on thermal management materials are becoming increasingly stringent. In the future, thermal conductive materials will trend toward higher thermal conductivity, lighter weight, and greater intelligence, such as developing new composite materials with self-healing capabilities and phase-change energy storage properties to adapt to more complex thermal management scenarios.
OSI New Materials will continue to focus on customer needs, relying on strong R&D capabilities and innovation, to continuously launch higher-performance, safer, and more reliable thermal management material solutions, helping the NEV industry move toward a more efficient, safe, and sustainable future.
